Posted 11 February 2013 - 11:48 AM
Hi Rod, sorry I didn't chime in earlier. It's a shame about the adjustable screws, but it's when unexpected **** like this happens during jobs that you really get more learning experience out of it. If you can't back the screw out from above or below, then there's not much you can do besides cutting/drilling them out (not so fun and won't be pretty), or rig up something to press them out like bearing cups on a bicycle.
You can make a pretty simple little press with some scrap wood, a dowel, and a clamp that lets you add gradual pressure (preferably not a cam-clamp). Bear with me since I don't have any pictures or measurements:
The upper block will need to be at least 1/4" bigger than the bushing all the way around, at least 1" tall, and have a hole drilled in it also slightly bigger than the bushing and about 1/2" deep.
The bottom block can be a little bit smaller than the other one, and will need to be drilled and have a section of dowel (slightly smaller in diameter to the bushing) protruding 1/4-3/8" from the block. Dry fit the two to make sure there's enough room in the upper block to fit the bottom dowel and the bushing as well.
Let your soldering iron heat up, and then hold it on the bushing for a few minutes to soften the glue (like you would when removing a fret, but longer since you want the metal will retain some heat). You should be able to push them right out after that, maybe having to add a little heat to the bushing again if it starts to cool off too quickly.
And if that all goes smoothly you should be able to fill the holes and continue on with the repair, can't wait to see how it comes out.
Hope this helps you out,
Travis